Modelling the dynamics of cutting during turning

This thesis presents an approach to cutting dynamics during turning based upon the mechanism of deformation of work material around the tool nose known as "ploughing". Starting from the shearing process in the cutting zone and accounting for "ploughing", new mathematical models relating turning force components to cutting conditions, tool geometry and tool vibration are developed. These models are developed separately for steady state and for oscillatory turning with new and worn tools. Experimental results are used to determine mathematical functions expressing the parameters introduced by the steady state model in the case of a new tool. The form of these functions are of general validity though their coefficients are dependent on work and tool materials. Good agreement is achieved between experimental and predicted forces. The model is extended on one hand to include different work material by introducing a hardness factor. The model provides good predictions when predicted forces are compared to present and published experimental results. On the other hand, the extension of the ploughing model to taming with a worn edge showed the ability of the model in predicting machining forces during steady state turning with the worn flank of the tool. In the development of the dynamic models, the dynamic turning force equations define the cutting process as being a system for which vibration of the tool tip in the feed direction is the input and measured forces are the output The model takes into account the shear plane oscillation and the cutting configuration variation in response to tool motion. Theoretical expressions of the turning forces are obtained for new and worn cutting edges. The dynamic analysis revealed the interaction between the cutting mechanism and the machine tool structure. The effect of the machine tool and tool post is accounted for by using experimental data of the transfer function of the tool post system. Steady state coefficients are corrected to include the changes in the cutting configuration with tool vibration and are used in the dynamic model. A series of oscillatory cutting tests at various conditions and various tool flank wear levels are carried out and experimental results are compared with model—predicted forces. Good agreement between predictions and experiments were achieved over a wide range of cutting conditions. This research bridges the gap between the analysis of vibration and turning forces in turning. It offers an explicit expression of the dynamic turning force generated during machining and highlights the relationships between tool wear, tool vibration and turning force. Spectral analysis of tool acceleration and turning force components led to define an "Inertance Power Ratio" as a flank wear monitoring factor. A formulation of an on—line flank wear monitoring methodology is presented and shows how the results of the present model can be applied to practical in—process tool wear monitoring in • turning operations.

Avaliação de discos de corte de semeadora-adubadora em diferentes quantidades de cobertura vegetal

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Desempenho de discos de corte de semeadora-adubadora em diferentes quantidades de cobertura vegetal

The quality and efficiency in straw cutting are determinants in the sowing process, according to the occurrence of "tamp" and stops, the magnitude of the straw removal or even the known effects of the seed "envelopment" where the cutting mechanism can not cut the remaining straw. Thus, the objective of this study was to evaluate the performance of different mechanisms for straw cutting of a seeder individualized in different amounts of crop coverage artificially added in a clay soil. The experiment was conducted at Unesp – Sao Paulo State University in the Experimental Farm Lageado, belonging to the College of Agricultural Sciences - Unesp, Botucatu. The experimental design was split plot with four replications, with main plots consisting of five quantities of black oat straw, in area with no-tillage system and subplots of three opening furrows mechanisms, which are: plane disk (PD), corrugated disk (CD) and wavy disk (WD). The wavy disk provided greater rolling resistance, reducing the speed of the set (tractor and equipment). The plane cutting disk showed the highest values of mobilized soil area, deeper penetration into the soil, requiring lower values of vertical force and higher values of lateral force. Regarding the type of waste and doses used, they offered no resistance to cutting and there was no change in the horizontal force on straw.

SEM and EDS Characterisation of Layering TiOx Growth onto the Cutting Tool Surface in Hard Drilling Processes of Ti-Al-V Alloys

10 p.

Formation Mechanism Of Lamellar Chips During Machining Of Bulk Metallic Glass

The uniqThe unique lamellar chips formed in turning–machining of a Vit 1 bulk metallic glass (BMG) are found to be due to repeated shearband formation in the primary shear zone (PSZ). A coupled thermomechanical orthogonal cutting model, taking into account force, free volume and energy balance in the PSZ, is developed to quantitatively characterize lamellar chip formation. Its onset criterion is revealed through a linear perturbation analysis. Lamellar chip formation is understood as a self-sustained limit-cycle phenomenon: there is autonomous feedback in stress, free volume and temperature in the PSZ. The underlying mechanism is the symmetry breaking of free volume flow and source, rather than thermal instability. These results are fundamentally useful for machining BMGs and even for understanding the physical nature of inhomogeneous flow in BMGs.ue lamellar chips formed in turning–machining of a Vit 1 bulk metallic glass (BMG) are found to be due to repeated shearband.

Cutting edge: Langerin+ dendritic cells in the mesenteric lymph node set the stage for skin and gut immune system cross-talk.

Topical transcutaneous immunization (TCI) presents many clinical advantages, but its underlying mechanism remains unknown. TCI induced Ag-specific IgA Ab-secreting cells expressing CCR9 and CCR10 in the small intestine in a retinoic acid-dependent manner. These intestinal IgA Abs were maintained in Peyer\'s patch-null mice but abolished in the Peyer\'s patch- and lymph node-null mice. The mesenteric lymph node (MLN) was shown to be the site of IgA isotype class switching after TCI. Unexpectedly, langerin(+)CD8alpha(-) dendritic cells emerged in the MLN after TCI; they did not migrate from the skin but rather differentiated rapidly from bone marrow precursors. Depletion of langerin(+) cells impaired intestinal IgA Ab responses after TCI. Taken together, these findings suggest that MLN is indispensable for the induction of intestinal IgA Abs following skin immunization and that cross-talk between the skin and gut immune systems might be mediated by langerin(+) dendritic cells in the MLN.

Multiscale simulation of nanometric cutting of single crystal copper and its experimental validation

In this paper a multiscale simulation study was carried out in order to gain in-depth understanding of machining mechanism of nanometric cutting of single crystal copper. This study was focused on the effects of crystal orientation and cutting direction on the attainable machined surface quality. The machining mechanics was analyzed through cutting forces, chip formation morphology, generation and evolution of defects and residual stresses on the machined surface. The simulation results showed that the crystal orientation of the copper material and the cutting direction significantly influenced the deformation mechanism of the workpiece materials during the machining process. Relatively lower cutting forces were experienced while selecting crystal orientation family {1 1 1}. Dislocation movements were found to concentrate in front of the cutting chip while cutting on the (1 1 1) surface along the View the MathML source cutting direction thus, resulting in much smaller damaged layer on the machined surface, compared to other orientations. This crystal orientation and cutting direction therefore recommended for nanometric cutting of single crystal copper in practical applications. A nano-scratching experiment was performed to validate the above findings.

Effective cutting of a quantum spin chain by bond impurities

Spin chains are promising media for short-haul quantum communication. Their usefulness is manifested in all those situations where stationary information carriers are involved. In the majority of the communication schemes relying on quantum spin chains, the latter are assumed to be finite in length, with well-addressable end-chain spins. In this paper we propose that such a configuration could actually be achieved by a mechanism that is able to effectively cut a spin ring through the insertion of bond defects. We then show how suitable physical quantities can be identified as figures of merit for the effectiveness of the cut. We find that, even for modest strengths of the bond defect, a ring is effectively cut at the defect site. In turn, this has important effects on the amount of correlations shared by the spins across the resulting chain, which we study by means of a scattering-based mechanism of a clear physical interpretation. © 2013 American Physical Society.

Investigation of chip formation and fracture toughness in orthogonal cutting of UD-CFRP

Features of chip formation can inform the mechanism of a machining process. In this paper, a series of orthogonal cutting experiments were carried out on unidirectional carbon fiber reinforced polymer (UD-CFRP) under cutting speed of 0.5 m/min. The specially designed orthogonal cutting tools and high-speed camera were used in this paper. Two main factors are found to influence the chip morphology, namely the depth of cut (DOC) and the fiber orientation (angle 휃), and the latter of which plays a more dominant role. Based on the investigation of chip formation, a new approach is proposed for predicting fracture toughness of the newly machined surface and the total energy consumption during CFRP orthogonal cutting is introduced as a function of the surface energy of machined surface, the energy consumed to overcome friction, and the energy for chip fracture. The results show that the proportion of energy spent on tool-chip friction is the greatest, and the proportions of energy spent on creating new surface decrease with the increasing of fiber angle.

Starch metabolism in Leucoagaricus gongylophorus, the symbiotic fungus of leaf-cutting ants

Leucoagaricus gongylophorus, the symbiotic fungus of the leaf-cutting ants, degrades starch, this degradation being supposed to occur in the plant material which leafcutters forage to the nests, generating most of the glucose which the ants utilize for food. In the present investigation, we show that laboratory cultures of L. gongylophorus produce extracellular alpha-amylase and maltase which degrade starch to glucose, reinforcing that the ants can obtain glucose from starch through the symbiotic fungus. Glucose was found to repress a-amylase and, more severely, maltase activity, thus repressing starch degradation by L. gongylophorus, so that we hypothesize that: (1) glucose down-regulation of starch degradation also occurs in the Atta sexdens fungus garden; (2) glucose consumption from the fungus garden by A. sexdens stimutates degradation of starch from plant material by L. gongylophorus, which may represent a mechanism by which Leafcutters can control enzyme production by the symbiotic fungus. Since glucose is found in the fungus garden inside the nests, down-regulation of starch degradation by glucose is supposed to occur in the nest and play a part in the control of fungal enzyme production by leafcutters. (c) 2005 Elsevier GmbH. All rights reserved.

Digging effort in leaf-cutting ant queens (Atta sexdens rubropilosa) and its effects on survival and colony growth during the claustral phase

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Yeasts and filamentous fungi carried by the gynes of leaf-cutting ants

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Advanced ceramics: Evaluation of the mechanism of stock removal and ground surface quality

The aim of this work is to evaluate the mechanism of stock removal and the ground surface quality of advanced ceramics grounded by a plane tangential grinding process with diamond grinding wheels. The analysis of the grinding performance was done regarding the cutting surface wear behavior of the grinding wheel for ceramic workpieces. The discussion about the results emphasized the wear mechanism of the grinding wheel cutting surface and the cutting phenomenology of the grinding process. The grounded surface was evaluated using Scanning Electron Microscopy (SEM). © 1999 Society of Automotive Engineers, Inc.

Advanced ceramics: Evaluation of the mechanism of stock removal and ground surface quality

The aim of this work is to evaluate the mechanism of stock removal and the ground surface quality of advanced ceramics machined by a surface grinding process using diamond grinding wheels. The analysis of the grinding performance was done regarding the cutting surface wear behavior of the grinding wheel for ceramic workpieces. The ground surface was evaluated using Scanning Electron Microscopy (SEM). As a result it can be said that the mechanism of material removal in the grinding of ceramic is largely one of brittle fracture. The increase of the hmax can reduce the tangential force required by the process. Although, it results in an increase in the surface damage, reducing the mechanical properties of the ground component.

Cutting performance of diamond coated Si3N4 tool during turning

Silicon nitride cutting tools have been used successfully for machining hard materials, like: cast irons, nickel based alloys, etc. However these cutting tools with diamond coating present little information on dry turning operations of gray cast iron. In the present work, Si3N4 square inserts was developed, characterized and subsequently coated with diamond for dry machining operations on gray cast iron. All experiments were conducted with replica. It was used a 1500, 3000, 4500 m cutting length, feed rate of 0.33 mm/rev and keeping the depth of cut constant and equal to 1 mm. The results show that wear in the tool tips of the Si3N4 inserts, in all cutting conditions, was caused by both mechanical and chemical processes. To understand the tool wear mechanisms, a morphological analysis of the inserts, after experiments, has been performed by SEM and optical microscopy. Diamond coated PVD inserts showed to be capable to reach large cutting lengths when machining gray cast iron. © (2010) Trans Tech Publications.